Remote drill fluid supply system and method

ABSTRACT

A drill fluid supply device includes a drill fluid container. A pump is fluidly coupled to the drill fluid container. The pump configured to move drill fluid from within the container. A drill fluid supply receiver is configured to receive wireless signals to control at least the pump.

TECHNICAL FIELD

This invention relates to ground drilling equipment. Specifically, thisinvention relates to a remotely-controlled drill fluid supply system.

BACKGROUND

Directional drilling is a useful technique for several procedures suchas utility installation, etc. One common type of directional drilling ishorizontal directional drilling, where a drill stem of a drill device isextended essentially horizontally to form passages under structures suchas roads for example.

Drilling fluids, such as bentonite fluid, are often used duringdirectional drilling to lubricate the drill hole, help break up themedium being drilled, flush debris from within the drill hole, etc.Typically, such drilling fluids are pumped through a conduit from adrill fluid supply device to a drill head, from which the drillingfluids are discharged into the drill hole. A conductor cable typicallyruns between the drill fluid supply device and the drill device toenable a user at the drill device to control at least some aspects ofthe drill fluid supply device, such as whether drilling fluid is beingsupplied to the drill head, for instance.

The use of such a conductor cable to link the drill fluid supply devicewith the drill device has several drawbacks. For instance, a conductorcable is prone to mechanical failure due to the constant threat ofjostling, kicking, stretching, crushing, cutting, etc. present at adrilling work site. Additionally, exposure to the elements and drillingfluids, contaminants, and other such potentially corrosive materials,increases the likelihood of electrical/mechanical failure of theconductor cable, by creating a short in the conductor cable, corrodingportions of the conductor cable, etc. Moreover, the spacing between thedrill fluid supply device and the drill device is limited, at least inpart, by the length of the conductor cable. Also, the amount of drillfluid supply device control is limited by the size (i.e., the width ordiameter) of the conductor cable. Typically, the more control desired atthe drill device, the larger the conductor cable. Generally, a conductorcable capable of providing the connection for a full range of control istoo large to be practical in field use.

What is needed is a drill fluid supply system that is less susceptibleto at least some of the hazards of the drilling environment, while atthe same time providing for an increased amount of control of the drillfluid supply device and a greater amount of spacing between the drilldevice and the drill fluid supply device, if desired, while maintainingpracticality of the drill fluid supply device in the field.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a drilling apparatus according to an embodiment of theinvention.

FIG. 2 shows a drill device according to an embodiment of the invention.

FIG. 3 shows a drill interface according to an embodiment of theinvention.

FIG. 4 shows views of a drill fluid supply device according to anembodiment of the invention.

FIG. 5 a is a block diagram of a drilling apparatus according to anembodiment of the invention.

FIG. 5 b is a block diagram of a drilling apparatus according to anembodiment of the invention.

FIG. 6 is an enlarged fragmentary view of a drill head of the drillingapparatus of FIG. 1.

FIG. 7 is a block diagram of a method of operating a wirelesslycontrolled drill fluid supply device.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings which form a part hereof, and in which is shown,by way of illustration, specific embodiments in which the invention maybe practiced. In the drawings, like numerals describe substantiallysimilar components throughout the several views. These embodiments aredescribed in sufficient detail to enable those skilled in the art topractice the invention. Other embodiments may be utilized andstructural, or logical changes, etc. may be made without departing fromthe scope of the present invention. In the following descriptions, adrill stem is defined to include any component that is advanced from adrilling device. A drill rod is defined as a section of pipe, solidmaterial, etc. where sections of drill rod are coupled together to forma main part of a drill stem. Various drill stem components such as adrilling blade holder, a sonde housing, etc. can be attached to thefront end of a number of drill rods during one embodiment of a typicaldrilling operation.

Referring to FIGS. 1, 2, and 6, there is shown a drilling apparatus 100including a drill device or rig 70 and a drill fluid supply device 10.The drill rig 70 typically includes a plurality of drill rods 74 forforming a drill stem 71 to perform a drilling operation. Although anexample of a directional drill device 70 is used in the followingdescriptions and is shown in the attached figures, other ground drillsutilizing a number of sections of drill stem are also contemplated to bewithin the scope of the invention.

Referring specifically to FIGS. 2 and 6, a drill head 72 is disposed atthe front of the drill stem 71 and includes a cutting blade thereon. Thedrill stem 71 typically includes a passage (not shown) therethrough forconducting drill fluid (not shown) to the drill head 72. The drill head72 includes a drill fluid outlet 72 a (see FIG. 6) for discharging drillfluid within a drill hole for lubrication, debris removal purposes, andthe like.

Referring now to FIG. 2, the drill device 70 is shown on a track system76 for positioning the drill device 70. Although a track system 76 isshown, other systems are also possible for use in positioning the drilldevice 70. Wheeled systems, or combinations of tracked and wheeledsystems are examples of acceptable positioning systems. Although apositioning system is shown in the embodiment of FIG. 2, the inventionis not so limited. Embodiments without a positioning system are alsopossible.

Referring to FIGS. 1-3, one example of the drill device 70 includes anoperator seat 77 having a drill interface 90 disposed proximate thereto.The drill interface 90 of this example includes a plurality of controlsto allow an operator to control at least some aspects of the operationof the drilling apparatus 100. In one example, the drill device 70further includes a drill control unit 80, which will be described ingreater detail below. While a seat is shown in the embodiment of FIGS. 1and 2, the invention is not so limited. Embodiments without a seat arealso possible.

Referring now to FIGS. 1 and 4, one example of the drill fluid supplydevice 10 of the present invention includes a frame or platform 11 onwhich the below-described components of the drill fluid supply device 10are mounted. The components include a drill fluid container or tank 12for containing drill fluid used for a drilling operation. The drillfluid is mixed within the tank 12 by a mixing pump or mixer 16. A highpressure pump or drill fluid pump 14 is fluidly coupled to the tank 12to conduct drill fluid from the tank 12 to the drill device 70,specifically, the drill stem 71. A drill fluid filter 20 is includedwith the drill fluid supply device 10 to remove at least some ofcontaminants and/or oversized particulates from the drill fluid. In oneexample, a hose 24 is used to fluidly couple the drill fluid supplydevice 10 and the drill device 70, and, more specifically, the tank 12and the drill stem 71. The hose 24, in one example, is stored on a reel26 and is reeled out to connect an end of the hose 24 to the drilldevice 70, located remotely from the drill fluid supply device 10. Thedrill fluid supply device 10 further includes a container 18 for holdingclean water or antifreeze. An engine 22 is included to provide power tothe drill fluid supply device 10. The engine 22 in one example is adiesel engine, although it is within the spirit and scope of the presentinvention that the drill fluid supply device 10 is powered differently.For instance, a different type of combustion engine could be used withthe drill fluid supply device 10, or, alternatively, the drill fluidsupply device 10 could be electrically powered by a battery, a separate,stand-alone generator, or the local power grid (i.e., plugged into anelectrical outlet).

In one example, the drill fluid supply device 10 includes a drill fluidsupply control unit 30, as will be described in more detail below. Inone example, the control unit 30 includes a drill fluid supply interface40 including user controls for controlling at least some aspects of theoperation of the drilling apparatus 100.

Referring to FIG. 5 a, in one example, a wireless control system for thedrilling apparatus 100 includes the drill fluid supply control unit 30and the drill control unit 80. The drill fluid supply control unit 30includes a receiver 32, a transmitter 34, a processor 36, and the drillfluid supply interface 40. In one example, the receiver 32 and thetransmitter 34 are combined in a transceiver 31, although thisconfiguration is not intended to be limiting. The transmitter 34 isconfigured to send wireless signals 38 to the drill device 70, and thereceiver 32 is configured to receive wireless signals 88 from the drilldevice 70. The processor 36 is configured to process the wirelesssignals 88 received and create appropriate control signals forcontrolling particular aspects of the operation of the drill fluidsupply device 10. The processor 36 in one example is further configuredto direct the transmitter 34 to send the wireless signals 38corresponding to input from the user using the drill fluid supplyinterface 40. In another example, the processor 36 is configured toprocess control signals directly from the drill fluid supply interface40 to allow a user at the drill fluid supply device 10 to controlparticular aspects of the operation of the drill fluid supply device 10.

In one example, the drill control unit 80 includes a receiver 82, atransmitter 84, a processor 86, and the drill interface 90. In oneexample, the receiver 82 and the transmitter 84 are combined in atransceiver 81, although this configuration is not intended to belimiting. The transmitter 84 is configured to send wireless signals 88to the drill fluid supply device 10, and the receiver 82 is configuredto receive wireless signals 38 from the drill fluid supply device 10.The processor 86 is configured to process the wireless signals 38received and create appropriate control signals for controllingparticular aspects of the operation of the drill device 70. Theprocessor 86 in one example is further configured to direct thetransmitter 84 to send the wireless signals 88 corresponding to inputfrom the user using the drill interface 90. In another example, theprocessor 86 is configured to process control signals directly from thedrill interface 90 to allow a user at the drill device 70 to controlparticular aspects of the operation of the drill device 10.

In this way, the drill interface 90 can be used to control variousaspects of the operation of the drill device 70 and/or the drill fluidsupply device 10, and the drill fluid supply interface 40 can be used tocontrol various aspects of the operation of the drill fluid supplydevice 10 and/or the drill device 70. The aspects of operationcontrollable are discussed in more detail below.

The wireless signals 38, 88 can be of any appropriate type for relayinginformation between the drill device 70 and the drill fluid supplydevice 10. The wireless signals 38, 88 can be one or a combination ofcontinuous signals, pulsed signals, and one-directional signals. In oneexample, the type of the wireless signals 38, 88 varies according tooperator inputs and selected functions. Signal strength and frequencyare not limited herein, although it is noted that such parameters aregenerally constrained and/or limited by Federal CommunicationsCommission (FCC) guidelines and appropriate licensing. It iscontemplated that the signal strength and frequency is capable of beingvaried to enable adjustment thereof, for instance, if spacing betweenthe drill device 70 and the drill fluid supply device 10 orenvironmental factors, such as noise, terrain, or the like causecommunication problems between the drill device 70 and the drill fluidsupply device 10.

Referring now to FIG. 5 b, the wireless control system for the drillingapparatus 100 is similar to the wireless control system shown in FIG. 5a, but differs at least in that it includes an optional repeater/relaystation 60. While only one repeater/relay station 60 is shown, it iswithin the spirit and scope of the present invention that more than onerepeater/relay station 60 is used with the wireless control system forthe drilling apparatus 100. The repeater/relay station 60 aids intransmitting the wireless signals 38, 88 between the drill device 70 andthe drill fluid supply device 10. If communication is lost between thedrill device 70 and the drill fluid supply device 10, a shutdown of theboring operation could result. One or more repeater/relay stations 60can be used with the wireless control system to improve communicationbetween the drill device 70 and the drill fluid supply device 10, forinstance, when signal interference is relatively high and/or when adistance between the drill device 70 and the drill fluid supply device10 is relatively long. In one example, where the drill device 70 and thedrill fluid supply device 10 are separated by building construction,trees, or the like, one or more repeater/relay stations 60 can bepositioned to relay the wireless signals 38, 88 between the drill device70 and the drill fluid supply device 10. In another example, the one ormore repeater/relay stations 60 are positioned to be in direct line ofsite to both the drill device 70 and the drill fluid supply device 10.In yet another example, the one or more repeater/relay stations 60 areplaced along the distance between the drill device 70 and the drillfluid supply device 10 to reduce the distance the wireless signals 38,88 need to travel in a single span, thereby increasing the effectivenessof the wireless signals 38, 88.

As stated above, various aspects of the operation of the drill fluidsupply device 10 and the drill device 70 can be controlled from one orboth of the user interfaces 40, 90. The following lists include at leastsome aspects controllable wirelessly. It is noted that the wirelesscontrol of additional aspects of operation for either the drill device70 of the drill fluid supply device 10, which are not listed below, iscontemplated in the present invention.

Aspects of operation controllable from the drill device 70 include, butare not limited to:

-   -   1. Start the drill fluid pump engine.    -   2. Stop the drill fluid pump engine.    -   3. Start the mixing engine.    -   4. Stop the mixing engine.    -   5. Start the drill fluid pump 14.    -   6. Stop the drill fluid pump 14.    -   7. Stop the supply of drill fluid to the drill device 70.    -   8. Start the supply of drill fluid to the drill device 70.    -   9. Increase the volume of drill fluid supplied to the drill        device 70.    -   10. Decrease the volume of drill fluid supplied to the drill        device 70.    -   11. Increase the maximum pressure of drill fluid supplied to the        drill device 70.    -   12. Decrease the maximum pressure of drill fluid supplied to the        drill device 70.    -   13. Start the mixing pump 16.    -   14. Stop the mixing pump 16.    -   15. Increase the volume of the mixing pump 16.    -   16. Decrease the volume of the mixing pump 16.    -   17. Increase the drill fluid concentration.    -   18. Decrease the drill fluid concentration.    -   19. “Lock” the drill fluid supply device 10 so as to be        controlled only from the drill device 70.    -   20. “Unlock” the drill fluid supply device 10 so drill fluid        controls may be done other than from the drill device 10.    -   21. “Lock” the drill fluid supply device 10 so as to be shut        down (stopped).    -   22. “Unlock the drill fluid supply device 10 so it can be        operated.

It is noted that the above list is in no particular order. It is furthernoted that at least some, if not all, of the above-listed controllableaspects can be operated in an automatic fashion dependent uponparameters the user inputs into the drill processor 86 using either thedrill fluid supply interface 40 or the drill interface 90. For instance,the user could run the drilling apparatus 100 in an automatic mode, thedrill fluid supplied to the drill stem 71 could be cut off automaticallywhenever an additional drill rod 74 is added to or removed from thedrill stem 71. Alternatively, the user could run the drilling apparatus100 in a manual mode, in which the drill fluid would have to manuallyshut down and restarted when adding additional drill rods 74 to thedrill stem 71. The above example is intended for illustrative purposesonly and is not intended to be limiting. As such, it is within thespirit and scope of the present invention that various other aspects ofthe operation of the drill fluid supply device 10 be controllable ineither automatic or manual modes.

Aspects of operation controllable from the drill fluid supply device 10include, but are not limited to:

-   -   1. Stop the drill engine.    -   2. Stop the supply of drill fluid to the drill device 70.    -   3. Notify the drill operator regarding a lack of drill fluid        supply (volume being supplied to the drill device 70).    -   4. Notify the drill operator regarding a lack of drill fluid        supply (available drill fluid in tank 12).    -   5. Notify the drill operator regarding a failure on drill fluid        supply device 10, (examples are fluid levels, overheat        condition, overpressure condition, and the like).    -   6. Engage “drill head lockout” device.

It is noted that the above list is in no particular order. It is furthernoted that, in a manner similar to that described above, at least some,if not all, of the above-listed controllable aspects can be operated inan automatic fashion dependent upon parameters the user inputs into thedrill fluid supply processor 36 using either the drill fluid supplyinterface 40 or the drill interface 90.

Referring to FIG. 7, in another example, a method 110 of operating awirelessly controlled drill fluid supply device 10 includes a step 120of positioning a drill fluid supply device 10 spaced from a drill device70. It is contemplated that the drill fluid supply device 10 can bespaced any distance from the drill device 70, although, in one example,the drill fluid supply device 10 is spaced within approximately 300 feetfrom the drill device 70. Advantageously, the drill device 70 isanchored in a location in which a drilling operation is desired and thedrill fluid supply device 10 is positioned close to a road or in anotherrelatively easily accessible area. The method 110 further includes astep 130 of sending a wireless signal 88 from a drill transmitter 84coupled to the drill device 70. Step 140 of the method 110 includesreceiving the wireless signal 88 at the drill fluid supply device 10.The method 110 further includes a step 150 of processing the wirelesssignal 88 to create a control signal for controlling the drill fluidsupply device 10. In one example, the step 150 includes a step 190wherein a drill fluid flow rate is controlled. In another example, thestep 150 includes a step 200 wherein a drill fluid pressure iscontrolled. It is contemplated that further aspects of operation of thedrill fluid supply device 10 including, but not limited to, the list ofaspects above, can also be controlled in the method 110.

In one example, the method 110 further includes a step 160 of sending awireless signal 38 from a drill fluid supply transmitter 34 remote fromthe drill device 70. Step 170 of the method 110 includes receiving thewireless signal 38 at the drill device 70. The method 110 furtherincludes a step 180 of processing the wireless signal 38 to create acontrol signal for controlling the drill device 70. It is contemplatedthat further aspects of operation of the drill device 70 including, butnot limited to, the list of aspects above, can also be controlled in themethod 110.

In this way, the wirelessly controlled drill fluid supply device 10 isless susceptible to at least some of the hazards of the drillingenvironment, while at the same time providing for an increased amount ofcontrol of the drill fluid supply device 10 and a greater amount ofspacing between the drill device 70 and the drill fluid supply device10, if desired, while maintaining practicality of the drill fluid supplydevice 10 in the field. The wireless control eliminates the need for acontrol cable on the ground between the drill fluid supply device 10 andthe drill device 70, thereby eliminating the possibility of the cablebeing damaged, for instance, by workers driving or walking over thecable; equipment or debris falling on the cable; water, solvents, orother fluids corroding the cable, etc. Additionally, the wirelesscontrol of the present invention allows for a greater number of aspectsof operation of the drill fluid supply device 10 to be controlled fromthe drill device 70 (and vice versa). When using a control cable betweenthe drill fluid supply device 10 and the drill device 70, thediametrical size of the cable necessarily had to be increased as thenumber of aspects wished to be controlled were increased. At a certainpoint, the cable would become to large to be used practically in adrilling operation. The wireless system eliminates this obstacle byallowing any number of aspects to be controlled. Also, the wirelesssystem of the present invention allows the drill fluid supply device 10and the drill device 70 to be spaced apart, for instance, 300 feet apartwithout requiring a reel having 300 feet of cable thereon. The wirelesssystem of the present invention allows the drill fluid supply device 10to be placed, for instance, along side of a road or in anotherrelatively easily accessible area spaced from the area in which thedrill device 70 is anchored for performing a drilling operation withoutthe necessity of running a potentially bulky and awkward control cabletherebetween. While it is true that a hose 24 generally must still bereeled out from the drill fluid supply device 10 in order to fluidlyconnect the drill fluid supply device 10 with the drill device 70 inorder to perform a drilling operation, the wireless system describedherein eliminates the further need to reel out a control cable toelectrically couple the drill fluid supply device 10 and the drilldevice 70, thereby saving time on the job site and, in turn, savingmoney.

While a number of advantages of embodiments described herein are listedabove, the list is not exhaustive. Other advantages of embodimentsdescribed above will be apparent to one of ordinary skill in the art,having read the present disclosure. Although specific embodiments havebeen illustrated and described herein, it will be appreciated by thoseof ordinary skill in the art that any arrangement which is calculated toachieve the same purpose may be substituted for the specific embodimentshown. This application is intended to cover any adaptations orvariations of the present invention. It is to be understood that theabove description is intended to be illustrative, and not restrictive.Combinations of the above embodiments, and other embodiments will beapparent to those of skill in the art upon reviewing the abovedescription. The scope of the invention includes any other applicationsin which the above structures and fabrication methods are used. Thescope of the invention should be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled.

1. A drill fluid supply device, comprising: a drill fluid container; apump fluidly coupled to the drill fluid container, the pump configuredto move drill fluid from within the container; and a drill fluid supplyreceiver configured to receive wireless signals to control at least thepump.
 2. The drill fluid supply device of claim 1, further comprising adrill fluid supply processor electrically connected to the drill fluidsupply receiver and the pump, the drill fluid supply processorconfigured to process the wireless signals received by the drill fluidsupply receiver and send a control signal to the pump.
 3. The drillfluid supply device of claim 2, wherein the wireless signals are sent bya drill transmitter of a drill device.
 4. The drill fluid supply deviceof claim 2, further comprising a drill fluid supply transmitter fortransmitting wireless signals to a drill device.
 5. The drill fluidsupply device of claim 4, wherein the drill fluid supply receiver andthe drill fluid supply transmitter are combined to form a drill fluidsupply transceiver.
 6. The drill fluid supply device of claim 4, whereinthe drill device further includes a drill receiver for receivingwireless control signals from the drill fluid supply transmitter.
 7. Thedrill fluid supply device of claim 6, wherein the drill device furtherincludes a drill processor electrically connected to the drill receiver,the drill processor configured to process the wireless signals receivedby the drill receiver and send a control signal to the drill device. 8.The drill fluid supply device of claim 6, further comprising a drillfluid supply transmitter for transmitting wireless signals to the drilldevice.
 9. The drill fluid supply device of claim 8, wherein the drillreceiver and the drill transmitter are combined to form a drilltransceiver.
 10. The drill fluid supply device of claim 1, wherein thepump moves the drill fluid to a drill device.
 11. The drill fluid supplydevice of claim 1, further comprising a drill fluid supply interfaceconfigured to send wireless signals to a drill receiver to control adrill device.
 12. A drilling apparatus, comprising: a drill device; adrill fluid supply device spaced from and fluidly coupled to the drilldevice; a drill transmitter coupled to the drill device; a drill fluidsupply receiver coupled to the drill fluid supply device and configuredto receive wireless drill fluid supply control signals sent by the drilltransmitter; a drill fluid supply transmitter coupled to the drill fluidsupply device; a drill receiver coupled to the drill device andconfigured to receive wireless drill control signals sent by the drillfluid supply transmitter; and a drill fluid supply processorelectrically connected to the drill fluid supply receiver and configuredto process the drill fluid supply control signals and control operationof the drill fluid supply device in response to the drill fluid supplycontrol signals.
 13. The drilling apparatus of claim 12, wherein thedrill device includes a drill interface.
 14. The drilling apparatus ofclaim 12, wherein the drill fluid supply device includes a drill fluidsupply interface.
 15. The drilling apparatus of claim 12, wherein thedrill device includes a drill head having a drill fluid outlet.
 16. Thedrilling apparatus of claim 12, wherein the drill fluid supply deviceincludes a container, a pump, and a mixer.
 17. The drilling apparatus ofclaim 12, wherein the drill fluid supply processor controls at least oneof a pump and a mixer of the drill fluid supply device.
 18. A method ofoperating a wirelessly controlled drill fluid supply device, comprising:positioning a drill fluid supply device spaced from a drill device;sending a wireless signal from a drill transmitter coupled to the drilldevice; receiving the wireless signal at the drill fluid supply device;and processing the wireless signal to create a control signal forcontrolling the drill fluid supply device.
 19. The method of claim 18,further comprising: sending a wireless signal from a drill fluid supplytransmitter remote from the drill device; receiving the wireless signalat the drill device; and processing the wireless signal to create acontrol signal for controlling the drill device.
 20. The method of claim18, wherein a drill fluid flow rate is controlled.
 21. The method ofclaim 18, wherein a drill fluid pressure is controlled.